On Monday, May 2, 2016 at 1:50:08 AM UTC+1, John Doe wrote:
> Andre Jute <> wrote:
>
> > John Doe wrote:
> >
> >> If you already have powerful cordless tools, making a cordless drill
> >> powered bike is dirt cheap. My new bike uses a Dewalt DCD995 for $90
> >> (US). That's $90 for the gearing, the brushless motor, the
> >> controller, the battery holder, and the rugged case that holds it all
> >> together. The rugged batteries are from your tools and effortlessly
> >> removable.
> >
> > Next you want to add two right angle drill gears so you can get the
> > drill under the frame and snugged up to the tubes of the frame instead
> > of sticking out vulnerably like that.
>
> I've been thinking about this for years. The new one sticks out pretty
> far, partly because it's a hammerdrill. But the method for holding the
> drill and attaching it to the bottom bracket isn't going to change here.
> And that probably excludes using a right angle. That's assuming the
> bracket can handle the torque. But even if not, I'll try using a brace
> (wire or whatever).
Okay, you're building an electric motorbike, not an electrically assisted bicycle.
Bear with some background for a moment. In electrically assisted bicycles, the so-called pedelecs (though pedelecs now have a legal meaning of limited power but I'll use the word here to mean electrically assisted bicycle, any power), there is a clutch mechanism for gradual torque take-up, automatically operated, not under the rider's control, plus electronic controls which can be one of two types. They are either based on a torque sensor (Panasonic Bosch, expensive, proprietary, protected by defended patents) or altogether electronic and merely mimicking some kind of an assumed universal usage torque curve. I have the second one because the first is attached only to limp motors on unappetising bikes. It works well enough with motors up to 350W. I have other sophisticated software so that I can run the bike with zero assistance, thottle assistance under my manual control, or on any of nine preset assistance levels from very low to "get the fuck out of my way on that hill"; since I have fourteen gears in my Rohloff box from stump-pulling to three overdrives, you can see that it is overkill. On switch-on the lowest of the nine levels of assistance is automatically switched in; I know how to make the software do anything I want but I haven't yet killed that default because I normally leave uphill from my front door and my bike and painting gear together is probably over thirty kilograms. A Rohloff chain is best run pretty slack, but otherwise you can imagine a single speeder or hub gearbox setup, no tensioner.
Now we come to the relevant point. In operation I've found that setting off from standstill on the default automatically switched-in assistance, even at the lowest of its nine levels, definitely jerks the transmission, especially in low gears where the torque multiplication is greatest -- and the Rohloff low gears are reaaaaal low. So I normally switch out the default initial preset assistance and use the throttle for whatever assistance is required to set the bike rolling.
On my previous, less powerful motor, and fitted to the front hub rather than the bottom bracket as the present motor, I didn't fit the pedelec controls, using only the throttle, and had now problem with operating 250W smoothly at all times.
I therefore conclude that
a) if you hammer drill has some kind of clutch such as was fitted to a nice pedestal drill at a small engineering works in which I once invested,
b) and/or
c) you can move the drill's speed trigger to the handlebar and make it operate relatively smoothly, perhaps by lengthening the lever
you probably don't need anything more.
Certainly, people on endless-sphere operate motors exactly like mine at well over 750W on precisely the same control software, and you don't hear a great deal about wrecked sprockets or hubs, so I also think that James is very likely right, in steel bike components are good for quite a bit of power. I don't have any ali in my drive chain, only steel and stainless steel, and despite the motor I've since 2002 trebled my once-dismal mileage on transmission parts by upgrading to German engineering in the gearbox, stainless cogs, and KMC X8 chains with special shaping of the rivets. Operating on throttle rather than preset assistance at takeoff is not from fear of wrecking external components but to protect my expensive gearbox from undue disturbance.
> I have two current concerns... Easily and neatly cutting a square 1/2 inch
> hole in a 3 3/8 inch thick aluminum disk. That's no big deal. The second
> is a little more technical, that's providing spring tension in the
> drivetrain so that power can be applied without worrying about jolting
> things when the sprocket catches up to the wheel speed. I think that can
> be done by modifying an ordinary chain tensioner. It hasn't wrecked my
> current bike, but this one's more powerful.
Mmm. If you fit a more powerful spring to a chain tensioner, it will also jerk back more powerfully. I've ridden a power-assisted derailleur bike and found the constant hesistation in response to the throttle irritating, and often followed by a sudden short speed surge which is disconcerting in traffic. I wonder if, in the light of what I said above, a zero tensioner installation might not work with merely a bit of slack in the chain.
If the tensioner is found to be essential, what you really want is a reversing resist that is fast-reacting in one direction and slow to react in the other. A small air or hydraulic damper will probably work better than a spring for your chain tensioning.
Apologies if you've already been there and back.
Andre Jute
Some problems are intrinsically more interesting than others